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Old 10-22-2018, 07:50 PM   #1
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400 Cummins Exhaust Manifold Replacement tricks

# 3 cyl leaking on my 2007 8.8 400 hp engine,going to replace all gaskets. Have all new OEM parts. I am a retired auto tech with lots of experience on gas stuff but none of this stuff.
Gonna soak all bolts with PB Blaster several days before with a little tapping on the bolt heads to loosen things up. I have all the tools to remove broken bolts,just trying not to do so!
Thanks to all
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Old 10-22-2018, 08:03 PM   #2
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PB Blaster is good stuff, one year I Soaked wheel lug nuts on my salt water boat trailer all summer with liquid wrench, these had not been off in like 20 years, at the end of summer they came off with 1/2 impact like new, so liquid wrench is good also, sounds like you know what you are doing, good luck.
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Old 10-22-2018, 08:52 PM   #3
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If lucky and none break. Put a longer bolt in front and rear holes...slide manifold on those about 1/2 inch, then you can slide the new gaskets into place. Removing the manifold can open up lots of new issues.

Soaked mine heavily twice a day, four days, they all came out ok.

Good luck
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Old 10-24-2018, 10:01 PM   #4
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PB blaster has worked the best for me. Restored my 69 Barracuda and used it a lot. Give it a little time to work! Also used it on my 5.7 Cummins in the Dually and it worked great on the exhaust bolts!
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Old 10-25-2018, 04:39 AM   #5
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Quote:
Originally Posted by taz4028 View Post
# 3 cyl leaking on my 2007 8.8 400 hp engine,going to replace all gaskets. Have all new OEM parts. I am a retired auto tech with lots of experience on gas stuff but none of this stuff.
Gonna soak all bolts with PB Blaster several days before with a little tapping on the bolt heads to loosen things up. I have all the tools to remove broken bolts,just trying not to do so!
Thanks to all
I found it helpful to have a board to lay across the engine access opening in the bedroom. That allowed me to reset my chest on the board while reaching both arms down to work. I used a board again last month when replacing all the radiator hoses so decided to keep it for future use. It is hanging on the wall in my garage.

Bob
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Old 11-15-2018, 11:12 AM   #6
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Job Done!!!

Just completed a successful of replacing all 6 exhaust manifold gaskets!!!!
Soaked all bolts with PB Blaster everyday the week before,not one single broken bolt. Used OEM gaskets and bolts,torqued to 32 ftlbs. Not a bad job for a retired gas mechanic,"bolts is bolts"
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Old 11-16-2018, 03:58 AM   #7
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Quote:
Originally Posted by taz4028 View Post
Just completed a successful of replacing all 6 exhaust manifold gaskets!!!!
Soaked all bolts with PB Blaster everyday the week before,not one single broken bolt. Used OEM gaskets and bolts,torqued to 32 ftlbs. Not a bad job for a retired gas mechanic,"bolts is bolts"
Not one bolt broke huh??? If I were you I would go buy a lottery ticket...LOL. Glad ya did not have any problems. I am sure that's gonna be a problem for us as well in the near future.
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Old 11-25-2018, 07:13 AM   #8
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A big "Thanks" to you guys, I took a leap of faith, and replaced the exhaust manifold and even took the turbo off and checked the bearings. I did what you guys did with PB Blaster, but my luck ran out, the 4 bolts that connect the manifold to the turbo broke and had to be replaced. But not a big deal, cause I had the manifold and turbo on the bench and easy to work on. Estimated @ 3775.00, I escaped with parts only @ 896.00. Crack was between 3 & 4. Can't ask for anymore from this forum. Thanks again.
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Old 11-25-2018, 07:22 AM   #9
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Was going to say to buy the replacement turbo bolts. When we changed my manifold, they were the only bolts we had a problem with and ended up breaking them off to get them out. Glad you had success. Cheers.
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